Vehicle engine cradle structure

ABSTRACT

A vehicle engine cradle structure includes a front member, a rear assembly and a side member. The front member extends in a vehicle lateral direction and has a first outboard end and a second outboard end. The rear assembly extends in the vehicle lateral direction and has a first outboard area and a second outboard area opposite the first outboard area. The first side member has a first forward end, a first rearward end and a first forward outboard portion all being formed as a single monolithic unitary element. The first forward end is fixedly attached to the first outboard end of the front member. The first rearward end is fixedly attached to the first outboard area of the rear assembly. The first forward outboard portion extends in an outboard direction from the first outboard end of the front member defining an off-center impact area.

CROSS-REFERENCE TO RELATED APPLICATIONS

This non-provisional continuation application claims priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 17/339,667, filed on Jun. 4, 2021, the entire contents of which are hereby incorporated herein by reference.

BACKGROUND Technical Field

The present disclosure generally relates to a vehicle engine cradle structure. More specifically, the present disclosure relates to vehicle engine cradle structure that includes an off-center impact receiving area that is defined on elements of the engine cradle structure.

Background Information

Off-center impact receiving structures are being employed in many vehicle body structures. Typically, the off-center impact receiving structure is a separate member or members that are attached to existing frame elements or attached to portions of an engine cradle of a vehicle.

SUMMARY

One object of the present disclosure is to include an off-center impact receiving area (also referred to as an off-center impact area) as an integral part of an engine cradle where an element or elements of the engine cradle are formed and/or manufactured with the off-center impact area, rather than being an add on member or members.

Another object of the present disclosure is to provide an engine cradle with an off-center impart area that is part of side members of the engine cradle where the side members are provided with greater strength than front and rear portions of the engine cradle.

In view of the state of the known technology, one aspect of the present disclosure is to provide a vehicle engine cradle structure with a front member, a rear assembly and a first side member. The front member extends in a vehicle lateral direction perpendicular to a vehicle longitudinal direction and has a first outboard end and a second outboard end opposite the first outboard end. The rear assembly extends in the vehicle lateral direction and has a first outboard area and a second outboard area opposite the first outboard area. The first side member has a first forward end, a first rearward end and a first forward outboard portion all being formed as a single monolithic unitary element. The first forward end is fixedly attached to the first outboard end of the front member. The first rearward end is fixedly attached to the first outboard area of the rear assembly. The first forward outboard portion extends in an outboard direction from the first outboard end of the front member defining an off-center impact area.

Another aspect of the present disclosure is to provide a vehicle engine cradle structure that includes a front member, a rear assembly, a first side member and a second side member. The front member has a first outboard end and a second outboard end opposite the first outboard end. The rear assembly has a first outboard area and a second outboard area opposite the first outboard area. The first side member has a first forward end fixedly attached to first outboard end of the front member and a first rearward end fixedly attached to the first outboard area of the rear assembly. The first side member defines a first frame attachment location dimensioned and positioned to attach to a first frame element of a vehicle. The first frame attachment location is adjacent to the first outboard end of the front member. The first side member has a first forward outboard portion that extends in an outboard direction from the first frame attachment location. The first forward end, the first rearward end the first frame attachment location, the first forward outboard portion are all defined on a single monolithic unitary element that defines the first side member. The second side member has a second forward end fixedly attached to second outboard end of the front member and a second rearward end fixedly attached to second outboard area of the rear assembly. The second side member defines a second frame attachment location dimensioned and positioned to attach to a frame element of a vehicle. The second frame attachment location is adjacent to the first outboard end of the front member. The second side member has a second forward outboard portion that extends in an outboard direction from the second frame attachment location. The second forward end, the second rearward end the second frame attachment location, the second forward outboard portion are all defined on a single monolithic unitary element that defines the second side member. A first distance is defined between the first frame attachment location and the second frame attachment location. A second distance is defined between an outboard end of the first forward outboard portion and the first frame attachment location. The second distance is greater than 10 percent of the first distance and less than 15 percent of the first distance.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the attached drawings which form a part of this original disclosure:

FIG. 1 is a top schematic view of a vehicle with an engine cradle structure that includes an off-center impact receiving area depicted with a test barrier aligned to impact the off-center impact receiving area in accordance with an exemplary embodiment;

FIG. 2 is perspective view of the engine cradle structure that includes a front member, a rear assembly, a first side assembly and a second side assembly, with the first side assembly having a first off-center impact receiving area and the second side assembly having a second off-center impact receiving area in accordance with the exemplary embodiment;

FIG. 3 is perspective exploded view of the engine cradle structure showing the front member, the rear assembly, a first side member and a first lower side member of the first side assembly and, a second side member and a second lower side member of the second side assembly in accordance with the exemplary embodiment;

FIG. 4 is top view of the engine cradle structure showing the front member, the rear assembly, the first side member and the first lower side member of the first side assembly and, the second side member and the second lower side member of the second side assembly in accordance with the exemplary embodiment;

FIG. 5 is a perspective view of the first side member of the first side assembly shown removed from the engine cradle structure in accordance with the exemplary embodiment;

FIG. 6 is an inboard side view of the first side member of the first side assembly shown removed from the engine cradle structure in accordance with the exemplary embodiment;

FIG. 7 is a top view of the first side member of the first side assembly shown removed from the engine cradle structure in accordance with the exemplary embodiment;

FIG. 8 is a perspective view of the first lower side member of the first side assembly shown removed from the engine cradle structure in accordance with the exemplary embodiment;

FIG. 9 is an inboard side view of the first lower side member of the first side assembly shown removed from the engine cradle structure in accordance with the exemplary embodiment;

FIG. 10 is a top view of the first lower side member of the first side assembly shown removed from the engine cradle structure in accordance with the exemplary embodiment;

FIG. 11 is a perspective view of the engine cradle structure partially assembled showing the front member, the first side assembly and the second side assembly attached to one another in accordance with the exemplary embodiment;

FIG. 12 is a cross-sectional view of the first side assembly taken along the line 12-12 in FIG. 4 in accordance with the exemplary embodiment; and

FIG. 13 is a bottom view of the engine cradle structure in accordance with the exemplary embodiment.

DETAILED DESCRIPTION OF EMBODIMENTS

Selected embodiments will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

Referring initially to FIG. 1 , a vehicle 10 that includes a vehicle engine cradle 12 is illustrated in accordance with a first embodiment.

The vehicle 10 includes a vehicle body structure 14 having front side members 16. The front side member 16 are conventional vehicle frame elements that are rigidly attached via, for example, welding techniques to portions of the vehicle body structure 14. The front side members 16 extend forward from a portion of the vehicle body structure 14 that defines a passenger compartment 18. Since vehicle body structures, and front side members are conventional structures well known in the art, further description is omitted for the sake of brevity.

As shown in FIGS. 1 and 2 , the vehicle engine cradle 12 (hereinafter the engine cradle 12) is located beneath the front side member 16 and is attached thereto as described in greater detail below.

As shown in FIGS. 2-4 , the engine cradle 12 includes a front member 22, a rear assembly 24, a first side assembly 26 and a second side assembly 28.

The front member 22 extends in a vehicle side-to-side direction D_(S), also referred to as a vehicle lateral direction D_(S). The vehicle lateral direction D_(S) is perpendicular to a vehicle longitudinal direction DL of the vehicle 10. The front member 22 has a first outboard end 30 and a second outboard end 32 opposite the first outboard end 30.

The rear assembly 24 also extends in the vehicle lateral direction D_(S) perpendicular to the vehicle longitudinal direction DL. The rear assembly 24 has an upper portion 24 a and a lower portion 24 b that are welded to one another using any one of a variety of conventional welding techniques. The rear assembly 24 has a first outboard area 34 and a second outboard area 36 opposite the first outboard area 34. The first outboard area 34 and the second outboard area 36 are located along a forward edge of the rear assembly 24 at opposite ends thereof.

The front member 22 and the rear assembly 24 define a vehicle longitudinal centerline CL that coincides with a center line of the vehicle 10. A shown in FIG. 4 , the first outboard end 30 of the front member 22 defines a first lateral distance D₁ from the vehicle longitudinal centerline CL.

As shown in several of the drawings, the vehicle 10 and the engine cradle 12 define a vehicle inboard direction D₁ and a vehicle outboard direction Do, both defined relative to the vehicle longitudinal centerline CL. The vehicle 10 further defines a vehicle forward direction DF and a vehicle rearward direction DR.

As shown in FIG. 3 , the first side assembly 26 includes a first side member 40 (an upper member) and a first lower side member 42. The first side member 40 is shown removed from the engine cradle 12 in FIGS. 5, 6 and 7 .

The first side member 40 of the first side assembly 26 has a first forward end 44, a first rearward end 46 and a first forward outboard portion 48 all being formed as a single monolithic unitary element. The first forward end 44 is fixedly attached to the first outboard end 30 of the front member 22 in a manner described further below. The first rearward end 46 is directly fixedly attached to the first outboard area 34 of the rear assembly 24. The first forward outboard portion 48 extends in the outboard direction Do from the first outboard end 30 of the front member 22 and partially defines an off-center impact area A₁.

As shown in FIGS. 2 and 4 , the first side member 26 defines a first frame attachment location F₁ dimensioned and positioned to attach to the corresponding one of the front side members 16 (also referred to as the first frame element 16 of the vehicle 10) proximate a front end of the front side member 16. The first frame attachment location F₁ is adjacent to the first outboard end 30 of the front member 22.

As shown in FIG. 4 , the first forward outboard portion 48 of the first side member 26 extends in the outboard direction Do from the first frame attachment location F₁. The first forward outboard portion 48 has an outboard-most section 48 a (a front outboard corner thereof) that is a second lateral distance D2 from the first outboard end 30 of the front member 22, as measured in the vehicle lateral direction D_(S). The second lateral distance D2 can be equal to at least 35 percent of the first lateral distance D₁. The second lateral distance D2 can be equal to less than 45 percent of the first lateral distance D₁. In other words, the second lateral distance D2 is between 35 and 35 percent of the value of the first lateral distance D₁.

As shown in FIGS. 5-7 , the first side member 26 is further formed with a downwardly extending outboard side 50 and a downwardly extending inboard side 52 with an inboard extending flange 54. The downwardly extending outboard side 50, the downwardly extending inboard side 52, the inboard extending flange 54, the first forward end 44, the first rearward end 46 and the first forward outboard portion 48 all being formed as a single monolithic unitary element.

As shown in FIGS. 3 and 8-10 , the first lower side member 42 of the first side assembly 26 has a first lower forward end 60, a first lower rearward end 62, a first lower forward outboard portion 64, an inboard extending flange 66 and an outboard upwardly extending flange 68 that are all formed as a single monolithic unitary element.

The first lower forward end 60 is directly fixedly attached to the first outboard end 30 of the front member 22 via any of a variety of welding techniques. The attachment between the first lower forward end 60 and the first outboard end 30 of the front member 22 defines a first seam S₁ that is angularly offset from the vehicle forward direction DF defining an acute angle therebetween. The first lower rearward end 62 is directly fixedly attached to the first outboard area 34 of the rear assembly 24. The inboard extending flange 66 is directly fixedly attached to the inboard extending flange 54 of the downwardly extending inboard side 52 of the first side member 40 as shown in FIG. 12 , via any of a variety of welding techniques. The outboard upwardly extending flange 68 is directly fixedly attached to the downwardly extending outboard side 50 of the first side member 40, as shown in FIG. 12 via any of a variety of welding techniques.

The first lower forward outboard portion 64 of the first lower side member 42 further defines the off-center impact area A₁ with the first forward outboard portion 48 of the first side member 40.

With reference to FIGS. 3 and 4 , a description is now provided for the second side assembly 28. The second side assembly 28 is basically identical to the first side assembly 26, except that the second side assembly 28 is a symmetrical mirror image of the first side assembly 26. There are several attachment points on the second side assembly 28 that differ from those on the first side assembly 26. However, the structural features of the second side assembly 28 are basically the same as the first side assembly 28.

The second side assembly 28 includes a second side member 140 (an upper member) and a second lower side member 142. The second side member 140 has a second forward end 144, a second rearward end 146, a second forward outboard portion 148, a downwardly extending outboard side 150, a downwardly extending inboard side 152 and an inboard extending flange 154 all being formed as a single monolithic unitary element.

The second forward end 144 is fixedly attached to the second outboard end 32 of the front member 22. The second rearward end 146 is fixedly attached to the second outboard area 34 of the rear assembly 24. The second forward outboard portion 148 extends in the outboard direction Do from the second outboard end 32 of the front member 22 at least partially defining another off-center impact area A₂.

The second side member 140 defines a second frame attachment location F₂ dimensioned and positioned to attach to the corresponding one of the front side members 16 (frame element of a vehicle 10). The second frame attachment location F₂ is located adjacent to the second outboard end 32 of the front member 22.

The second forward outboard portion 148 of the second side member 28 extends in the outboard direction Do from the second frame attachment location F₂.

A third distance D3 is defined between the second frame attachment location F₂ of the second side member 140 and the first frame attachment location F₁ of the first side member 40. A fourth distance D4 is defined between the outboard end of the first forward outboard portion 48 and the first frame attachment location F₁. Further, the fourth distance D4 is also defined between the outboard end of the second forward outboard portion 148 and the second frame attachment location F₂, measured in the vehicle lateral direction D_(S).

As shown in FIG. 4 , the fourth distance D4 is greater than 10 percent of the third distance D3 and less than 15 percent of the third distance D3. Further, the second outboard end 32 of the front member 22 and the vehicle longitudinal centerline CL are spaced apart from one another by the first lateral distance D₁. As well, the second outboard end 32 of the front member 22 and the outboard end of the second forward outboard portion 148 are spaced apart from one another by the second lateral distance D2.

The second lower side member 142 has a second lower forward end 160, a second lower rearward end 162, a second lower forward outboard portion 164, an inboard extending flange 166 and an outboard upwardly extending flange 168 all being formed as a single monolithic unitary element.

The second lower forward end 160 is directly fixedly attached to the second outboard end 32 of the front member 22 via any of a variety of welding techniques thereby defining a second seam S₂. The second seam 52 is angularly offset from the vehicle longitudinal centerline CL defining an acute angle therebetween. The second lower rearward end 162 is directly fixedly attached to the second outboard area 36 of the rear assembly 24 via any of a variety of welding techniques. The inboard extending flange 166 of the second lower side member 142 is directly fixedly attached to an inboard extending flange 154 of the downwardly extending inboard side 150 of the second side member 140 via any of a variety of welding techniques. The outboard upwardly extending flange 168 of the second lower side member 142 is directly fixedly attached to the downwardly extending outboard side 164 of the second side member 140.

The second lower forward outboard portion 164 of the second lower side member 132 and the second forward outboard portion 148 of the second side member 140 together further define the off-center impact area A₂.

The engine cradle 12 is attached to the vehicle body structure 14 at frame attachment locations F₁, F₂, F₃, F₄, F₅ and F₆. Attachment structures (not shown) fix the engine cradle 12 to corresponding attachment locations defined along portions of the front side members 16 that extend downward from the front side members 16 and/or structures forward of the passenger compartment 18 in a conventional manner.

As shown in FIGS. 2 and 3 , the engine cradle 12 also includes engine attachment brackets 172 and 174. These brackets 172 and 174 are one example of various engine attachment brackets that can secure an engine and transmission (shown in FIG. 1 in phantom) to the engine cradle 12. It should be understood from the drawings and the description herein that the engine cradle 12 is not limited to inclusion of the brackets 172 and 174 and that other bracket configurations are possible depending upon the engine and transmission installed to the engine cradle 12.

As shown in FIGS. 2 and 3 , front facing surfaces of each of the first side member 40 and the second side member 140 include bumper assembly attachment brackets 176.

In the depicted embodiment, the engine cradle 12 is assembled with materials that have differing response to stress. For example, the front member 22 is made of a metallic material that has a predetermined tensile strength (yield strength) of approximately 370 MPa (megapascals). The rear assembly 24 is made of a metallic material that has a predetermined tensile strength (yield strength) of approximately 590 MPa. The first side assembly 26 and the second side assembly 28 are made of a metallic material that has a predetermined tensile strength (yield strength) of approximately 780 MPa. More specifically, the first side assembly 26 (including the first side member 40 and the first lower side member 42) and the second side assembly 28 (including the second side member 140 and the second lower side member 142) are each made of a metallic material with material components that differ from the front member 22 and the rear assembly 24. For example, the metal (a steel or steel alloy) used to manufacture the first side assembly 26 and the second side assembly 28 includes an amount of titanium that is less that 0.20% by weight and an amount of chromium that is below 0.10% by weight. Preferably, the metal material used to make the first side assembly 26 and the second side assembly 28 includes no more than 0.14% by weight of titanium and chromium.

As shown in FIGS. 6 and 9 show the the first side member 40 and the first lower side member 42 in an orientation that corresponds to their respective orientation when parts of the engine cradle 12. Specifically, the first forward end 44 of the first side member 40 is located higher above the ground than the first rear end 46. Similarly, the first lower forward end 60 of the first side member 40 is located higher above the ground than the first lower rearward end end 62. Correspondingly, the rear assembly 24 is located closer to the ground than the front member 22 with the engine cradle 12 installed to the vehicle 10 and the vehicle 10 being on level ground.

The engine cradle 12 described above is designed such that in response to an impact event between the barrier B shown in FIG. 1 and either one of the off-center impact areas A₁ and A₂ (in the area where the front bumper attachment brackets 176 are installed) impact energy is transmitted to other areas of the engine cradle 12. In particular, if the impact occurs along the off-center impact area A₁, impact energy is transmitted along the first side assembly 26 to the rear assembly 24 of the engine cradle 12. Since the engine cradle 12 is attached to the vehicle body structure 14, some of the impact energy is transmitted to the vehicle body structure 14. Another portion of the impact energy can possibly cause deformation of the first side assembly 26 in a central area thereof causing the first side assembly 26 to contact the engine and/or transmission, thereby further transmitting impact energy to the engine and transmission. If the impact occurs along the off-center impact area A₂, impact energy is transmitted along the second side assembly 28 to the rear assembly 24 of the engine cradle 12, and possibly deforming the second side assembly 28 causing the second side assembly 28 to contact the engine and transmission transmitting impact energy thereto.

Other than the features of the engine cradle 12 described above, there are numerous conventional components of the vehicle 10 and the vehicle body structure 14 that are well known in the art. Since such conventional components are well known in the art, these structures will not be discussed or illustrated in detail herein. Rather, it will be apparent to those skilled in the art from this disclosure that the components can be any type of structure and/or programming that can be used to carry out the present invention.

In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. Also, the terms “part,” “section,” “portion,” “member” or “element” when used in the singular can have the dual meaning of a single part or a plurality of parts. Also as used herein to describe the above embodiment, the following directional terms “forward”, “rearward”, “above”, “downward”, “vertical”, “horizontal”, “below” and “transverse” as well as any other similar directional terms refer to those directions of a vehicle equipped with the vehicle engine cradle. Accordingly, these terms, as utilized to describe the present invention should be interpreted relative to a vehicle equipped with the vehicle engine cradle.

The terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed.

While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. For example, the size, shape, location or orientation of the various components can be changed as needed and/or desired. Components that are shown directly connected or contacting each other can have intermediate structures disposed between them. The functions of one element can be performed by two, and vice versa. The structures and functions of one embodiment can be adopted in another embodiment. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such features. Thus, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents. 

What is claimed is:
 1. A vehicle engine cradle structure, comprising: a first side assembly of an engine cradle having an upper first side member and a first lower side member, with a forward end of the upper first side member and a forward end of the first lower side member defining an off-center impact area. 